Molded insulator



Patented Dec. l, 1953 MOLDED INSULATOR Maurice J. Gelpi, Baltimore, Md., assigner to Westinghouse Electric Corporation, East Pittsburgh, Pa., a corporation of iennsylvania Application January 29, 1949, Serial No. 73,474

2 Claims. 1

This invention relates to insulators and in particular to molded electrical insulators provided with metallic terminals or end fittings.

Eerste-fore the manufacture of elec'ically insulating structures embodying metallic terminals or end fittings has required expensive molding dies and complicated molding schedules. In many cases, the resulting product has been unsatisfactory because ci the low mechanical strength and variable electrical properties due to the inadvertent formation of cavities and voids in the molded members.

The object oi this invention is to provide a process for the preparation of electrical insulators having metallic terminals or iittings by a simple molding operation.

A further object of the invention is to provide a molded insulator having metallic terminals or fittings characterized by high strength and a dense resinous body having good electrical. insu lating characteristics,

Other objects of the invention will in part be obvious and will in part be apparent hereinafter. For a better understanding of the nature and objects of the invention, reference should be had to the following detailed description and drawing, in which:

Figure 1 is a vertical elevation partly in cross section and partly broken, and

Fig. 2 is a Vertical cross section illustrating the molding of the insulators.

In accordance with this invention, molded insulators provided with metallic terminals or f1ttings are produced with outstanding strength and electrically insulating properties. Referring to Fig. 1 of the drawing, there is illustrated a molded insulator Iii produced in accordance with the invention. The insulator comprises a wound outer shell or tube I2 composed of plurality of turns of a sheet of brous material impregnated and bonded together with a thermoset resin. The laminated construction of the outer tube l2 duces extremely high mechanical strength both in tension and in compression. A laminated tube also possesses high resistance to penetration by moisture providing the laminations forming the tube I2 are compacted together under high pressure, so that there are no voids between laminations and the laminations are well bonded to each other. The insulator Ill of the present invention is prepared with the tube l2 constituting more than 50% of the cross sectional arca across a diameter. The interior of the tube is a hollow cylinder portion It. Within the hollow cylinder portion I4 is disposed a highly compressed and solidified core it comprising macero-ted ber and a thermoset resin body. Preferably, though not necessarily, the resin in the core it and the tube l2 is the same resin, though the resins may be dissimilar as long as they are compatible with and bondable to each other. Disposed within the hollow cylinder portion ill at one end of the tube I2 is a metal tting lil having a roughened stem E@ while at the other end is another metallic iitting 22 having a roughened stem portion 24 also fitting within the hollow portion I4. The tting 22 has an external aperture 26 for fastening to electrically charged members. While the roughened stem portions t@ and are illustrated as being threaded, they may be knurled, grooved or otherwise mechanically treated to provide a surface capable of locking in securely with the resinous core It and the tube l2. rEhe stems 2li and 25 are of a diameter smaller than the hollow portion I il, so that they may readily slip therein and permit the ilow of resin between the stem and the tube I2 to secure the maximum adherence of the components into a rigid unitary structure.

It has been discovered that the molded insulator it may be prepared in accordance with a novel process employing only simple molding and other processing equipment to produce a molded insulation structure having outstanding physical and electrically insulating properties. The process first comprises rolling a sheet of fibrous material treated with a thermosettable resin into the tube l2. This may be accomplished in a number oi ways. A convenient method has been to roll the resin treated ibrous material on a collapsible steel mandrel with suilicient pressure to produce arelatively tightly wound tube. In some cases, the tube has been partially cured by subjecting it to heat while on the mandrel. However, full curing oi the wound tube it is to be avoided in the interest ci securing a better bonded nal structure. After having been formed or molded on the mandrel, the tube l2 may be removed and the ends trimmed to length and squared. The end fitting i3 is put into a cylindrical mold 32, as shown in Fig. 2, which is preferably a solid mold positioned on a base 3u. Then the wound tube i2 is introduced into the mold to fit over the stern it and against the litting lil. Thereafter a weighed amount of macerated or chopped brous material treated with thermosettable resin is put into the hollow Illto form the core I6. The core i6 may be iirst preformed under pressure to a diameter that will admit it sliding down the hollow Hl. However, this is not necessary.

Thereafter the other end fitting 22 is slid into bore 34 of a cylindrical mold 32 and a ram t6 is applied to the end oi the fitting 32 to force it against the core I6. For an insulator having an outer diameter oi 11/4l and a hollow it, of 1/2" diameter, pressures of from 100 to 500 pounds on the ram 36 are adequate, though higher' pressures may be employed.

The moldy 32 is provided with a heating jacket 38 provided with a plurality of heating elements 40, such as electrical resistance wire. Under the influence of heat and pressure, the resin in the core I6 fuses and flows and exerts an internal expanding pressure against the tube l2, forcing the tube I2 into Contact with the walls 32 of the mold. Furthermore, the fused resin permeates throughout the fibers of the core I6 and some of the macerated core flows up around the stems 20 and 24. The pressure on the fitting 2?. should be sufficient to seat it against the end of the tube i2. Under the continuing influence of heat, the resin present in the tube lit and the lling i6 thermosets. After having thermoset, the resin in the tube i2 and the core IG, the

molded insulator may be pushed out ci the mol-d 32- and the mold 32 reexnployed Ifor preparing more of the members.

It has been found that an important feature of the process enabling exceptionally strong and durable insulators to be molded resides in the f step of applying the ram pressure to the filling I6, whereby the filling expands laterally within the hollow i4 and forces the sheet fibrous noa-- terial, forming tube l2, outwardly. This puts tho sheet fibrous material into tension, eliminating wrinkled or buckled sheet material, enables the reinforcing properties of the sheet material tobe utilized to a maximum.

When molded as disclosed herein, it will be found that the insulators are characterized by a dense, void-free resinous body in which the tube laminations are well bonded together without Wrinkling.

It has been found that the use of woven or mat glass iiber as the sheet of nbrous material enables insulators of outstanding mechanical strength to be produced. The macerated filling or core I6 may be composed of the same fabric either choppedy or otherwise cut up into small pieces. However, there may be employed cotton or asbestos fabric or iibers treated with resin. A particularly satisfactory resin for both the tube I2 and the core i6 is a polyester resin. Polyester resins are particularly desirable for inn sulators of the type disclosed herein, because the polyester compositions thermoset without the evolution of water or gases and thereby gas pockets and voids are avoided. Polyester resinsl may comprise (a)l compounds containing at least two unsaturated groupsl C=C or they may comprise (bl anunsaturated alkyd resin dissolved in a poly merizable monomer having the groups II2C=C Examples of the former are monomeric diallyl phthalate, diallyl maleate, diallyl succinate, diallyl adipate, diallyl crotonate and methallyl crotonate. Examples of the latter type of composition are the esters produced by reacting an alpha, beta unsaturated dibasic acid, such as maleic acid, maleic anhydride, fumarie acid, and citraconic acid with a polyhydric alcohol, such, for example, as ethylene glycol, propylene glycol, castor oil and pentaerythrtol and dissolving the ester so produced in monomethacrylate, styrene, methyl methacrylate, diallyl phthalate, diallyl maleate or vinyl acetate. The polyester resins after being applied to the fibrous material may he partly cured or they may be employed while iiuid. Ordinarily, a catalyst particularly a peroxide, such as benzoyl peroxide or terbutyl perbenzoate in an amount of the order of 0.1% to 1% is applied to the polyester to expedite curing. A temperature of 100 C. for 15 minutes to 150 C. for 5 to 10 minutes will thermoset the compositions.

For an insulator made in accordance with the invention of a length of 61/" between the fitting 22 and the center of the bore 26 and an external diameter of 11/4, a dielectric breakdown of 45,000 volts was obtained. It had extremely high tensile and compressive strength: in tension 1800 pounds was required to cause failure.

While the drawing shows a cylinder of circular cross-section, it will be appreciated that the cross-section may be elliptical, polygonal or otherwise to suit requirements. Square crosssecton insulators constructed in accordance with this invention are contemplated.

Since certain changes may be made in the above invention, and different embodiments of the invention may be made without departing from the scope thereof, it is intended that all matter contained in the above-described disclosure shall be interpreted as illustrative and not in a limiting sense.

I claim as my invention:

l.. A molded cylindrical insulator comprising a tubular cuter shell composed of: a plurality of turns of sheet :fibrous material impregnated and bonded with a thermoset resin, the shell com.- prising at least 50% of the thickness of material along a diameter, the tubular outer shell having a central opening, a metallic fitting extA ding from each end, or the tubular shell, the ic ttings each having a rou 4`.cned stem .ending within central openhg, and a core disposed within the central. opening, the core comprising a thermoset macerated ber and resin body bonded to the tubular outer shell. and to the roughened stems, the. core applying an internal pressurev against. the tubular outer shell to put the turns of the sheet` fibrous material in tension whereby the turns of the. tube are relatively unwrinlrled, the tubular outer shell providing for high mechanical strength, resistance to moisture and good electrical insulating properties.

2. A molded cylindrical insulator comprising a tubular outer shell composed oi a plurality of turns of sheet glass ber mat impregnated and bonded with a thermoset polyester resin, the shell comprising at least 50% oi the thickness of material along a diameter, the tubular outer shell having a central opening, a metallic fitting extending from each end of the tubular shell, the metallic fittings each having a roughened stem extending within the central opening, and a core,

disposed within the central opening, the core` comprising a thermoset macerated iiber and polyester resin body bonded to the tubular outer shell and to the roughened stems, the core applying an internal pressure against the tubular outer shell to put the turns of the sheet iihrous material in tension whereby the turns of the tube are relatively unwrinlled, the tubular outer shell providing for high mechanical strength, resistance to moisture and good electrical insulating properties.

MAURICE J. GELPI.

(References on following page) Number Name Date Hubert Dec. 8, 1908 5 Kempton Set'. 14, 1920 Apple Mr. 14, 1922 Kempton Jly 29, 1924 Edgerton Aug. 12, 1924 Kempton Feb. 16, 1926 l0 Number 6 Name Date Burke Apr. 7, 1931 Burke Jan. 2, 1934 Mensur May '7, 1935 Houwink Feb. 21, 1939 Stewart Sept. 3, 1940 Herrick et al May 12, 1942 Megow et a1 Nov. 17, 1942 Cook May 11, 1948 

1. A MOLDED CYLINDRICAL INSULATOR COMPRISING A TUBULAR OUTER SHELL COMPOSED OF A PLURALITY OF TURNS OF SHEET FIBROUS MATERIAL IMPREGNATED AND BONDED WITH A THERMOSET RESIN, THE SHELL COMPRISING AT LEAST 50% OF THE TICKNESS OF MATERIAL ALONG A DIMETER, THE TUBULAR OUTER SHELL HAVING A CENTRAL OPENING, A METALLIC FITTING EXTENDING FROM EACH END OF THE TUBULAR SHELL, THE METALLIC FITTINGS EACH HAVING A ROUGHENED STEM EXTENDING WITH THE CENTRAL OPENING, AND A CORE DISPOSED WITHIN THE CENTRAL OPENING OF THE CORE COMPRISING A THERMOSET MACERATED FIBEB AND RESIN BODY BONDED TO THE TUBULAR OUTER SHELL AND TO THE ROUGHENED STEMS, THE CORE APPLYING AN INTERNAL PRESSURE AGAINST THE TUBULAR OUTER SHELL TO PUT THE TURNS OF THE SHEET FIBROUS MATERIAL IN TENSION WHEREBY THE TURNS OF THE TUBE ARE RELATIVELY UNWRINKLED, THE TUBULAR OUTER SHELL PROVIDED FOR HIGH MECHANICAL STRENGTH, RESISTANCE TO MOISTURE AND GOOD ELECTRICAL INSULTING PROPERTIES 